High aspect ratio template and method for producing same

Abstract

Millimeter to nano-scale structures manufactured using a multi-component polymer fiber matrix are disclosed. The use of dissimilar polymers allows the selective dissolution of the polymers at various stages of the manufacturing process. In one application, biocompatible matrixes may be formed with long pore length and small pore size. The manufacturing process begins with a first polymer fiber arranged in a matrix formed by a second polymer fiber. End caps may be attached to provide structural support and the polymer fiber matrix selectively dissolved away leaving only the long polymer fibers. These may be exposed to another product, such as a biocompatible gel to form a biocompatible matrix. The polymer fibers may then be selectively dissolved leaving only a biocompatible gel scaffold with the pores formed by the dissolved polymer fibers.

1. A method for manufacturing a scaffold comprising:
 immersing a matrix into a first solution, the matrix comprising a first polymer surrounding a plurality of second polymer members arranged in a desired distribution pattern within the first polymer with each of the plurality of second polymer members having a predetermined length, cross-sectional area and cross-sectional shape, the first polymer being soluble in the first solution, the plurality of second polymer members being soluble in a second solution and insoluble in the first solution wherein the first solution dissolves the surrounding first polymer; 
 immersing the plurality of members in a third solution in which the plurality of members are insoluble, the third solution forming a biocompatible matrix surrounding the plurality of members; and 
 immersing the plurality of members and surrounding biocompatible matrix in the second solution to thereby dissolve the plurality of members and create a plurality of conduits in the biocompatible matrix. 
 
     
     
       2. The method of  claim 1  wherein the first polymer is selected from a group of polymers comprising a polymethylmethacrylate polymer, a polystyrene polymer, and a polyvinyl alcohol polymer. 
     
     
       3. The method of  claim 2  wherein the first solution comprises polypropylene carbonate if the selected first polymer comprises polymethylmethacrylate, and comprises tetrahydrofuran if the selected first polymer comprises polystyrene, and comprises water if the selected first polymer comprises polyvinyl alcohol. 
     
     
       4. The method of  claim 1  wherein the plurality of second polymer members are selected from a group of polymers comprising a polymethylmethacrylate polymer, a polystyrene polymer, and a polyvinyl alcohol polymer, and wherein the second polymer is different from the first polymer. 
     
     
       5. The method of  claim 4  wherein the second solution comprises polypropylene carbonate if the selected second polymer members comprises polymethylmethacrylate, and comprises tetrahydrofuran if the selected second polymer members comprises polystyrene, and comprises water if the selected second polymer members polyvinyl alcohol. 
     
     
       6. The method of  claim 1  wherein the third solution is a biocompatible gel in liquid form. 
     
     
       7. The method of  claim 1 , wherein the scaffold is adapted to be implanted in a spinal column. 
     
     
       8. A method for manufacturing a polymer fiber template comprising:
 cutting a polymer matrix to a desired length, the matrix comprising a plurality of first polymer members arranged in a desired distribution pattern within a surrounding structure with each of the plurality of first polymer members having a predetermined cross-sectional area and cross-sectional shape; 
 immersing the matrix into a first solution, the first polymer being soluble in the first solution, wherein the first solution dissolves the plurality of first polymer members to thereby create a plurality of conduits; and 
 embedding or coating at least a portion of the plurality of conduits with an antibacterial agent. 
 
     
     
       9. The method of  claim 8  wherein the surrounding structure is a second polymer that is insoluble in the first solution. 
     
     
       10. The method of  claim 8  wherein each of the plurality of conduits has a first end and a second end, configured such that when the first end of the plurality of conduits is positioned in fluid communication with an unfiltered liquid, the polymer fiber template is adapted to filter the unfiltered liquid through the plurality of conduits to thereby generate a filtered liquid at the second end of the plurality of conduits. 
     
     
       11. A method for manufacturing a multi-component nanofiber template comprising:
 immersing a matrix into a first solution, the matrix comprising a supporting structure surrounding a first polymer member and a second polymer member arranged in a desired pattern within the supporting structure with each of the first and second polymer members having predetermined dimensions, the first polymer member being soluble in the first solution, the second polymer member being soluble in a second solution and insoluble in the first solution, and the supporting structure being insoluble in both the first solution and the second solution wherein the first solution dissolves the first polymer member to thereby create a first conduit in place of the first polymer member; 
 immersing the matrix in the second solution wherein the second solution dissolves the second polymer member to thereby create a second conduit in place of the second polymer member; and 
 depositing a P-type thermoelectric material into the first conduit, or depositing an N-type thermoelectric material into the second conduit, or both depositing a P-type thermoelectric material into the first conduit and depositing an N-type thermoelectric material into the second conduit. 
 
     
     
       12. The method of  claim 11 , wherein a P-type thermoelectric material is deposited into the first conduit and an N-type thermoelectric material is deposited into the second conduit, the method further comprising interconnecting the P-type thermoelectric material and the N-type thermoelectric material. 
     
     
       13. The method of  claim 11  wherein the first polymer member is selected from a group of polymers comprising a polymethylmethacrylate polymer, a polystyrene polymer, and a polyvinyl alcohol polymer. 
     
     
       14. The method of  claim 13  wherein the first solution comprises polypropylene carbonate if the selected first polymer member comprises polymethylmethacrylate, and comprises tetrahydrofuran if the selected first polymer member comprises polystyrene, and comprises water if the selected first polymer member comprises polyvinyl alcohol. 
     
     
       15. The method of  claim 11  wherein the second polymer member is selected from a group of polymers comprising a polymethylmethacrylate polymer, a polystyrene polymer, and a polyvinyl alcohol polymer, and wherein the second polymer is different from the first polymer. 
     
     
       16. The method of  claim 15  wherein the second solution comprises polypropylene carbonate if the selected second polymer member comprises polymethylmethacrylate, and comprises tetrahydrofuran if the selected second polymer member comprises polystyrene, and comprises water if the selected second polymer member comprises polyvinyl alcohol. 
     
     
       17. The method of  claim 11  wherein the matrix comprises a plurality of first polymer members and a plurality of second polymer members arranged in a predetermined array and surrounded by the supporting structure wherein:
 immersing the matrix into the first solution comprises dissolving the plurality of first polymer members and creating a plurality of first conduits in place of the plurality of first polymer members; and 
 immersing the matrix in the second solution comprises dissolving the plurality of second polymer members and creating a plurality of second conduits in place of the plurality of second polymer members. 
 
     
     
       18. The method of  claim 17  further comprising depositing a first material into the plurality of first conduits. 
     
     
       19. The method of  claim 18  further comprising depositing a second material into the plurality of second conduits. 
     
     
       20. The method of  claim 17  wherein the surrounding structure is a third polymer that is soluble in a third solution. 
     
     
       21. The method of  claim 20 , further comprising placing the matrix in the third solution to thereby dissolve the surrounding structure.